CN101506390A - A method for the commercial production of iron - Google Patents
A method for the commercial production of iron Download PDFInfo
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- CN101506390A CN101506390A CNA2007800309460A CN200780030946A CN101506390A CN 101506390 A CN101506390 A CN 101506390A CN A2007800309460 A CNA2007800309460 A CN A2007800309460A CN 200780030946 A CN200780030946 A CN 200780030946A CN 101506390 A CN101506390 A CN 101506390A
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/14—Multi-stage processes processes carried out in different vessels or furnaces
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/004—Making spongy iron or liquid steel, by direct processes in a continuous way by reduction from ores
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/08—Making spongy iron or liquid steel, by direct processes in rotary furnaces
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/12—Making spongy iron or liquid steel, by direct processes in electric furnaces
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
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Abstract
A method for the production of iron from an iron oxide-containing material includes contacting an iron oxide-containing material with a particle size distribution range with a *<90> of less than 2mm, with a carbon-containing material with a particle size distribution range with a *<90> of less than 6mm, in a commercial scale reactor at a temperature of between 900 DEG C and 1200 DEG C for a contact time sufficient to reduce the iron oxide to iron.
Description
Technical field
The present invention relates to a kind of industrialized preparing process of iron, also relate to a kind of reaction unit and the launch vehicle that in the suitability for industrialized production of iron, use.
Background technology
In history, iron is by obtaining with the charcoal reducing iron oxides.In this process, charcoal both as thermal source also as reductive agent.The alloy that product is made up of the carbon of about 96.5% iron and about 3.5%.Charcoal was replaced by coke afterwards.Now, mainly be under about 2000 ℃ temperature in blast furnace by carbothermic reduction rhombohedral iron ore (Fe
2O
3) and magnetite (Fe
3O
4) iron ore produces iron.In this process, be fed to stove top with the carbon of iron ore, coke form with such as the such flux of Wingdale, one warm air is sent into the stove bottom.In stove, the oxygen reaction in coke and the air blast generates carbon monoxide, and carbon monoxide becomes iron with reduction of iron ore, and carbon monoxide is oxidized to carbonic acid gas in this process.The iron of producing in this process is called as the pig iron.Because high gas flow rates in the blast furnace, ferric oxide and coke are necessary for more coarse particle form, and preferred particle size is greater than about 6mm.If the particle size major part is less than 6mm, feed can be blown out blast furnace top by air-flow.In addition, have one to prevent to form that hot cold belt forms and the relevant built-in problem of blast furnace operation, it may cause reversed reaction and competing reaction.
In the mining of iron ore and carbon, transportation and the storage, easily produce a large amount of brown iron oxides and carbon dust (being often referred to ickings).And fine croci both was produced as the byproduct of copper production, for example, and in the situation of the Freeport of the Phalaborwa in South Africa mining company or Indonesia (Grasberg), also as roasting FeS in the gas washing in SA production
2Byproduct be produced.These fine raw material powders provide the starting material source for iron production.Yet because as above, unless these raw materials are exactly particulate state at first, they can not be used for blast furnace, do not have economic feasibility again but make it become particulate state.Purpose of the present invention addresses this problem exactly.
Summary of the invention
According to an aspect of the present invention, provide the method for the raw material production iron that a kind of usefulness contains ferric oxide, this method is included in the industrial-scale reactor, under the temperature between 900 ℃ to 1200 ℃, will have
Less than the raw material that contains ferric oxide of the particle size distribution of 2mm with have
Less than the carbonaceous raw material contact certain hour of the particle size distribution of 6mm, making iron oxide reduction is iron.
Preferably, all basically raw material that contains ferric oxide all is reduced into and is iron.
One skilled in the art will appreciate that
Mean that at least 90% material has less than specified particle size, just,
For meaning at least 90% particulate matter, 2mm has particle size less than 2mm.
Usually also write a Chinese character in simplified form into d90.
" industrial-scale reactor " meaning is an energy with the conventional reactor of producing iron of speed of 1000kg/h at least.
Contain the raw material of ferric oxide
Should be less than 1mm.Preferably, the raw material that contains ferric oxide
Should be less than 500 μ m.
Carbonaceous raw material
Should be less than 2mm.Preferably, carbonaceous raw material
Should be less than 1mm.
Duration of contact should be between 30 to 360 minutes.Be preferably about 60 to 180 minutes duration of contact, more preferably about 120 minutes.
This method is included under the situation that flux (for example calcium oxide and unslaked lime) exists iron oxide-containing materials is contacted with carbon raw material.
Iron oxide-containing materials may be a spent ferric oxide.The waste product that produces in particularly iron ore exploitation, copper production or the gas washing in SA production.These raw materials typically have
Be particle size, form by rhombohedral iron ore or magnetite usually less than about 500 μ m.Carbon raw material may be waste coal or coal dust, is commonly referred to as the ickings that produces in the exploitation of coal and transportation.Carbon raw material also may be the waste material that produces in the distillation of coal or liquification.
Carbon raw material is preferably nonvolatile coal dust.This raw material typically has
Particle size less than about 6mm.
Temperature should be between 1000 ℃ to 1100 ℃ in the reactor, for example, and about 1050 ℃.
This method comprises by the external heat source reactor heating.Typically, reactor is by electrically heated.
By using external electric to reduce in about 1050 ℃ temperature, method of the present invention can be controlled meticulously.CO and CO
2Balance under differing temps is as follows:
CO CO
2
450℃： 2％ 98％
750℃ 76％ 24％
1050℃ 99.6％ 0.4％
Therefore by controlled temperature at 1050 ℃, CO/CO
2Balance is basically fully CO one side.
The method of the traditional making iron that carries out in blast furnace need use carbonaceous flux (as CaCO
3) improve CO in the stove
2Concentration.Yet this has not only improved gas velocity, because CaCO
3Decomposition be thermo-negative reaction, also increased energy requirement.CaCO
3Decomposition in about 900 ℃ of generations.
CaCO
3＝CaO+CO
2
Temperature: 500 ℃ 600 ℃ 700 ℃ 800 ℃ 900 ℃
mm?Hg：?0.11 2.35 25.3 168 760
FeSiO
3And Fe
2SiO
4Formation occur in more than 700 ℃, at SiO
2Need before active CaO and SiO with FeO chemical combination
2Reaction.
Iron oxide-containing materials is contacted comprise described raw material supply with predetermined amount in rotating cylindrical shaped reaction device or rotary kiln with carbon raw material, set the speed of rotation of reactor and angle make raw material in the residence time in reactor all basically ferric oxide be reduced into iron.
This method comprises and prevents the air admission reactor.
Can select the input speed of iron oxide-containing materials and carbon raw material and the operating temperature of reactor, make that the gas release that is caused by reduction by reactor causes airflow on surface speed low to be enough to prevent material carry secretly with reactor in the corresponding loss of iron oxide-containing materials and carbon raw material powder.Typically, airflow on surface speed is lower than 2ms
-1, be preferably about 1ms
-1
This method comprises the exhaust velocity of input speed, temperature of reactor and the reactor of control iron oxide-containing materials and carbon raw material, so that the carbon monoxide in the reactor reaches the concentration of steady state basically.
This method comprises the step of recovery from the excessive carbon monoxide of reactor discharging, and utilizes excessive carbon monoxide generate energy.The energy that produces can be used to reactor heating.
According to the product that the inventive method is produced, be granular iron at least at first with particle size identical with the particle size of iron oxide-containing materials.
This method comprises makes iron oxide-containing materials and slight excessive (for example: excessive approximately 5%-30%) carbon raw material contacts, product iron is separated from magnetic from excessive carbon raw material (for example: distill ickings), the smelting iron product obtains the soft steel that purity surpasses 99% mass percent.
Surpass 99% by magnetic except that the purity of the iron behind the carbon elimination is typical.This is the purity of soft steel.In addition, by adding an amount of chromium, nickel or manganese, can produce stainless steel product.
According to a further aspect in the invention, provide a kind of method from the raw material production iron that contains ferric oxide, this method comprises the use particle size distribution
In industrial-scale reactor, under high temperature, reduce particle size distribution less than the carbonaceous raw material of 6mm
The raw material that contains ferric oxide less than 2mm, this reduction has produced carbon monoxide, this method further is included under certain speed and the temperature raw material supply in reactor, from reactor, discharge carbon monoxide with certain speed, so that can in reactor, keep the basicly stable state of carbon monoxide concentration.
Iron oxide-containing materials and carbon raw material are as indicated above.
Iron oxide-containing materials and carbon raw material are fed in the reactor with certain speed, and the selection of this speed makes the carbon monoxide that produces in reduction process with less than about 2ms
-1Airflow on surface speed by reactor, be preferably about 1ms
-1
According to a further aspect in the invention, provide a kind of method from the raw material production iron that contains ferric oxide, this method is included in the industrial-scale reactor, uses particle size distribution
Carbonaceous raw material reduction particle size distribution less than 6mm
Less than the raw material that contains ferric oxide of 2mm, this method further comprise by certain speed with raw material supply in reactor, make reactor in hot operation, make the air-flow that causes by reduction discharge and airflow on surface speed in the reactor that causes less than 2ms
-1
Iron oxide-containing materials and carbon raw material are as indicated above.
Preferably, temperature between about 1000 ℃ to 1100 ℃, more preferably about 1050 ℃.
The preferred surface gas velocity is about 1ms
-1
Preferably, all basically iron oxide-containing materials all are reduced.
According to another aspect of the present invention, providing a kind of is suitable for particle size distribution
Carbonaceous raw material and particle size distribution less than 6mm
Less than the raw material that contains ferric oxide of the 2mm reaction unit of the suitability for industrialized production of contacted iron at high temperature, this reaction unit comprises the common cylindrical reactor that has entrance and exit and install around its longitudinal axis rotation, be used for reactor is heated to the heating unit of temperature between about 900 ℃ to 1200 ℃, device is installed in erecting device on the launch vehicle.
Heating unit can be the electric heater unit that is positioned at the reactor outside.This device can comprise be used for rotatable reactor drive unit.
This method extends to a kind of launch vehicle of desired reaction unit as mentioned that is equipped with.
Description of drawings
Now embodiment and the accompanying drawing according to the back illustrates the present invention, wherein
Fig. 1 has shown the side schematic view of the reactor that is used for the inventive method;
Fig. 2 has schematically represented the sectional view of the reactor of Fig. 1.
Embodiment
With reference to the accompanying drawings, Reference numeral 10 expressions are used for the reaction unit of the electrically heated rotary kiln version of method of the present invention.Stove 10 is included in the cylindrical reaction tubes 12 in the shell 14.Can find out among Fig. 2 that shell 14 has a square cross-section, its outside dimension is about 2 x 2m.Reactor 12 is installed on the support of representing with Reference numeral 16, is used for rotation.Feeder 18 is sent raw material to the inlet end 20 of reaction tubes 12.Feeder 18 has the labyrinth seal (not shown), enters reaction tubes 12 to prevent air-flow.
12 about 6m are long for reaction tubes, and diameter is about 1m, carries out electrically heated by the heating unit (not shown) in the shell 14.Stove 10 tilts from left to right as seen from the figure, and support 16 has a regulating mechanism (not shown), is used to increase or reduce the gradient or the angle of reaction tubes 12, and it changes the pass through speed of raw material by reaction tubes 12 with rotating speed.The exit end 22 of reaction tubes 12 is (not shown)s of sealing, contacts with granular iron product from reaction tubes 12 to prevent air.Support 16 has supporting leg 24, and it can be installed on the launch vehicle (not shown) so that the entire reaction device can be transported to the zone of spent ferric oxide and/or the storage of useless carbon.
Embodiment 1
The magnetite of the Phalaborwa mining company in the South Africa of Shi Yonging has following composition and distribution of sizes in the present embodiment:
Fe 66％
Fe
3O
4 91.2％
SiO
2 0.52％
Al
2O
3 1.08％
Sulphur 0.11%
Phosphorus 0.04%
The coal of 700kg (seeing Table 1) is produced the following non-volatile coal of 400kg:
(under reductive condition)
Table 1
Following equation is the regression equation of magnetite:
Fe
3O
4+4C＝3Fe+4CO(g)
With 1mol Fe
3O
4Be benchmark, can do following calculating:
1mol Fe
3O
4=231.54g, 91.2% purity=253.88g
4mol C=48g, 73% purity=65.75g
+ 50% excessive non-volatile coal=98.625g (not comprising the air in the rotation)
Reach a conclusion thus, 1 ton of magnetite of reduction needs the non-volatile coal of 388kg in the rotation.1 ton of magnetite comprises 10.8kg Al
2O
3With 5.2kg SiO
2The non-volatile coal of 388kg comprises 38.8kg SiO
2With 15.5kg Al
2O
3Total SiO
2=44kg=0.733kmol, total Al
2O
3=26.3kg=0.258kmol.If the lime of equimolar amount joins SiO
2And Al
2O
3, the sintering in the reduction will significantly reduce.Lime total requirement=0.991kmol CaO=55.5kg, 89% purity=62.4kg.Lime is ground into-500 μ m,
Also original mixture (based on 1 ton of magnetite) is as follows:
1 ton of magnetite (91.2%) (300 ℃ of dryings)
The non-volatile coal of 388kg (73%)
62kg lime(89%)
Be total to 1450kg
To be fed to 9.7m with the input speed of 300kg/h long 2.9 ton is gone back original mixture, in the reduction tube or rotary kiln of the inclination of 0.96m ID.Pipe rotates with 1.12rpm, is collected into the cylinder from the raw material that is in control.Through about 2 hours, collected initial raw material (seeing the following form 2).Pipe has 3 roasting zones, i.e. the zone 1 of intake zone, the zone 2 of intermediate zone, the zone 3 of discharge region.Measure each regional temperature and be recorded in the table 2.Feed end and discharge end at pipe prevent that with 2 machine hammers raw material from adhering to the side.The angle of pipe is equivalent to make the contraction in length 5mm of the long pipe of 1m.
Table 2
Close stove after 10 hours, burning is from the CO of the CO generation of pipe discharging
2Flame burnt away 1 hour.Very fast, other 147kg shifts out from rotary oven, keeps 179kg at the bottom of the rotating bed.These materials reoxidize and are dropped owing to lacking CO.Material in the cylinder 1 and 16 also is dropped.
According to the regression equation that provides above, reductase 12 53.9g magnetite raw material can cause 112g CO (g) loss fully.Therefore, 1450kg also original mixture to emit 441kg CO (g).Be equivalent to 30.4% mass loss.According to the efficient of the rotary seal that is used to reduction tube and reduction reaction excluding air, in the mass loss of reductive steady-state process usually at 34-37%.Take measures to prevent that the hot iron powder from reoxidizing.Usually carrying out water-cooled by the chamber that iron powder is entered realizes.
The good reduced iron powder (from magnetite or rhombohedral iron ore) that adopts the inventive method to obtain typically has following XRD figure:
CaO 2-5％
Rhombohedral iron ore (Fe
2O
3)-2%
Iron 85-89%
Magnetite (Fe
3O
4) 0-1%
Carbon 2-6%
Wustite (FeO) 1-4%
If before fusing, reduced powder is separated with other non-magnetic impurity magnetic with excessive carbon, can obtain high-purity Fe (soft steel).Following table has shown the difference on the quality of magnetic fragment of reduced iron of the reduced powder of fusing and fusing.
The magnetic fragment of the reduced powder fusing of fusing
Fe 96-97％ >99％
C 2-3％ <0.25％
Si 1-2％ <0.25％
S 0.2-0.5% reduces by about 15% S
P 0.05-0.2% reduces by about 30% P
Reduced iron powder is fed to the gyromagnetic cylinder that rotating speed is 50rpm with 1kg/ minute speed, and the cylinder magneticstrength is 1200 Gausses, and the collection distance between magnetic and the non-magnetic material is 10mm.The ratio of magnetic and non-magnetic material typically is magnetic raw material and the 14-18% non-magnetic material of 82-86%.
Magnetic fragment in the reduced iron powder can melt with various stoves, for example: electric arc furnace, induction furnace or resistance furnace.
Usually the magnetic fragment comprises the metal of 78-82%, and gas loss is 3-6%.Magnetic powder mixes with the lime of 5-10% before entering stove usually.Help to dilute slag also except that P and S in the de-iron.Electric arc furnace and induction furnace are worked under well-oxygenated environment usually, and this helps to remove the P in the de-iron and make it to enter slag.The well-oxygenated environment (high FeO content) of common slag has stoped removes S from iron, this can finish in ladle subsequently.Typically from iron, remove the iron that the iron bag slag of S is used to melt with following ratio:
2% CaC
2(pulverizing)
1.5% CaF
2Powder
3% Al
2O
3Powder
8.5% lime (pulverizing)
0.4% Al piece
Different with electric arc furnace and induction furnace, the gas in the carbon resistance stove is reducing.According to the P content in the iron, as additive, be necessary to mix the Fe of 2-5% sometimes with lime
2O
3Powder with oxidation P, is absorbed in the basic slag it in the magnetic powder.Therefore available same slag extracts S and P simultaneously from iron.
By this method, can directly obtain the soft steel masterbatch from powdered iron ore, and without the intermediate pig iron (the method according to this invention becomes iron powder with powder reduction, and magnetic separates iron powder, evenly adds additive in the fusing of powder and controlled fusing forward direction magnetic powder).
Clean soft steel masterbatch (reinforcing bar or band steel), its S and P≤0.06%, C≤0.25% can be used to produce various dissimilar stainless steels, for example FeCr, FeMn, FeSi, FeV, FeMo, FeC by adding different alloys
3Deng alloy.Even these dissimilar alloys can be before fusing mix with magnetic powder (and lime) and obtain appropriate product after being incorporated in desulfurization and dephosphorization.
Following calculation specifications the capacity factor of process of the present invention:
The energy that adds thermal reduction mixture needs:
1 ton of magnetite is from 20 ℃ to 1050 ℃, Δ T=1030 ℃
CpMΔT＝1?x?1t?x?1030℃＝1030MJ
The non-volatile coal of 388kg is from 20 ℃ to 1050 ℃, Δ T=1030 ℃
CpMΔT＝1.7?x?0.388t?x?1030℃＝679.4MJ
62kg lime is from 20 ℃ to 1050 ℃, Δ T=1030 ℃
CpMΔT＝0.8?x?0.062t?x?1030℃＝
51.0MJ
Be total to 1760.4MJ
Energy at 1050 ℃ of reduced irons needs:
Fe
3O
4+4C＝3Fe+4CO(g) 2?734?MJ
Yet the magnetite that is used for present embodiment only is 91.2% purity=need 2493.4MJ.Typically, the quality of reduction back reservation is 66% (1450kg)=957kg reduced powder.
Usually, about 84% reducing powder is used as magnetic fragment recovery=804kg.
The energy that these powder of fusing need under 1535 ℃ is:
804kg+80kg additive=884kg is heated to 1535 ℃, Δ T=1515 ℃ from 20 ℃
CpMΔT＝0.6x0.884t?x?1515℃＝803.6MJ
Magnetic fragment (804kg)=643kg of at least 80% reclaims as iron.Fe (s) changes energy=247KJ/kg Fe that Fe (1) needs into, so 643kg iron needs 159MJ.
Total energy=the 5216.4MJ that needs is used to produce the iron of 643kg or iron 2.25MWh per ton.
The magnetite per ton of Phalaborwa mining company comprises the iron of 660kg.This means the rate of recovery of 643kg=97.4%.
As previously mentioned, the magnetite per ton of Phalaborwa mining company discharges 441kgCO (g) in reduction.Every kg CO (g) burns in air, discharges the energy of 10.2MJ.This means the energy that discharges 4498.2MJ in air when 441kgCO (gas) burns.
In non-volatileization of coal, the coal of about 700kg produces the non-volatility coal of 400kg.The energy that 400kg non-volatility coal need discharge is:
(700kg?x?28)-(400kg?x?25)
＝19600-10000
＝9600MJ
In the reduction of the magnetite of 1 ton of Phalaborwa mining company, need the non-volatility coal of 388kg, mean the energy that in non-volatileization process, needs to discharge 388/400 x 9600=9312MJ.
Total energy=13810MJ that the magnetite of 1 ton of Phalaborwa mining company of reduction need discharge.If 30% energy can be transformed into electric energy by evaporation, the energy that every 643kg Fe produces 4 143MJ or 1.79MWh/ ton iron can be recovered.This means that producing 75% of 1 ton of required energy of iron from then on obtains in the process.
Embodiment 2
The rhombohedral iron ore of the Sishen in the South Africa of Shi Yonging has following composition and distribution of sizes in the present embodiment:
Fe 63.1％
Fe
2O
3 90.2％
SiO
2 5.6％
Al
2O
3 1.98％
S 0.03％
P 0.14％
Following equation is represented the regression equation of rhombohedral iron ore:
Fe
2O
3+ 3C=2Fe+3CO (gas)
With 1mol Fe
2O
3Be benchmark, can do following calculating:
1mol Fe
2O
3=159.7g, 90.2% purity=177g
3mol C=36g, 73% purity=49.32g
+ 50% excessive non-volatile coal=73.97g (getting rid of the air in the rotation)
This shows that 1 ton of rhombohedral iron ore of reduction needs the non-volatile coal of 418kg in rotary oven.1 ton of rhombohedral iron ore comprises 19.8kg Al
2O
3With 56kg SiO
2The non-volatile coal of 418kg comprises 41.8kgSiO
2With 16.7kg Al
2O
3Total SiO
2=97.8kg=1.63kmol, total Al
2O
3=36.5kg=0.358kmol.The total CaO=1.988kmol=111.33kg that needs, 89% purity=125kg.
Also original mixture (based on 1 ton of rhombohedral iron ore) is as follows:
1 ton of rhombohedral iron ore (90.2%) (300 ℃ of dryings)
The non-volatile coal of 418kg (73%)
125kg lime(89%)
Be total to 1543kg
The same being reduced of magnetite among these raw materials and the embodiment 1 obtains similar result.
Realize that the required minimum pipe of airflow on surface speed＜1m/s can be by following calculating (the supposition space be approximately 1):
450kg CO=16kmol gas
Under STP, 1mol gas=22.4l (273k)
Therefore, 16kmol gas=16000 x 22.4l
＝358.4m
3
1050 ℃ of (1323k)=1
323X 358.4m
3
273
＝1736.86m
3
If reduction reaction has carried out surpassing 1 hour, airflow on surface speed will be 0.482m
3/ s.
Volume/s=area x speed
Therefore,
If v=1m/s, the diameter of pipe is:
If use diameter to be 1m, the length pipe as 6m, the volume of pipe can arrive 4700l.15% end load is exactly 705l.The volume density of incoming mixture is about 2g/ml, and therefore, the 705l load will have 1410kg.This means that airflow on surface speed will be lower than 1ms if per hour 1450kg mixing raw material (embodiment 1) is fed to and has the as above rotary kiln of size under 1050 ℃ of temperature
-1
Method of the present invention, as described, the method for making iron with traditional blast furnace compares, and mainly contains following difference.At first, replaced blast furnace with rotary kiln.The refractory lining that does not need blast furnace, method of the present invention is carried out in the stainless steel tube reactor.The used charging of blast furnace has the particle size greater than 6mm usually, and the charging of method of the present invention is the waste material that has less than the 0.5mm particle size.By mineral fuel and the inner heating drum wind furnace of carbon monoxide, and the rotary kiln external electric.In addition, blast furnace is surpassing 10ms
-1Gas velocity under operate, and method of the present invention low typically less than 2ms
-1Operate under the airflow on surface speed, be pulled away to avoid final powdered reaction thing.In addition, blast furnace is operated under about 200 ℃ to 1600 ℃ thermograde, and method of the present invention, as described, all processes all carries out under 1050 ℃ constant temperature.The product that the traditional drum wind furnace obtains is a molten iron, and the product that the inventive method obtains is the iron powder of particulate.In addition, the byproduct of blast furnace is a carbonic acid gas, manipulation require carbonaceous flux in blast furnace, and the byproduct of method of the present invention is the carbon monoxide that can be used to produce electric current, method of the present invention needs metal oxide flux.Importance economically is, blast furnace has the fixed position, and reactor of the present invention can be transported to the zone that needs it.Therefore, owing to starting material needn't be transported to reactor expense is reduced widely.
Another advantage of the present invention is that the granular iron product has on a small quantity or do not have dust.An advantage of the present invention is that ground ferric oxide and coal have high surface-area, has improved reduction ratio, has reduced the residence time in rotary kiln.This means again with blast furnace compares, and output has improved.The applicant estimates to be about half of cost of producing the pig iron per ton with the traditional drum wind furnace with the cost that the inventive method is produced iron per ton.
The XRD coatings of the reduction material of embodiment 1 show has high reduction ratio (ratio of Fe and FeO).This is because the method according to this invention can be controlled reduction process.Further advantage of the present invention be exactly product be iron powder rather than molten mass.This just can wherein add additive at iron powder fusion forward direction.In this, it is very difficult adding additive and mixed additive simultaneously in molten mass.This means again by mixing such as Fe in fusion forward direction iron powder
2O
3Oxygenant, can effectively control the carbon level after the reduction.Before fusion, also can in iron powder, add other metal or metal oxide.The present invention is special, and advantage is, by before fusion from iron product magnetic remove excessive carbon, the quality of iron is significantly brought up to the specification that satisfies soft steel.This has caused increasing substantially of value of the product.As indicated above, can produce stainless steel ingot rather than pig iron equally.Therefore since can be in the iron oxide reduction process direct production stainless steel, and melting process in the middle of not needing further, the very big raising that the value of product obtains.This is that the stainless method of existing production is significantly improved.The present invention further advantage is, unlike traditional method, method of the present invention is not used the carbon monoxide that forms in the reduction process and oxygen reaction and inner generate energy.Method of the present invention has produced pure relatively carbon monoxide byproduct, and it can be used as the outside fuel that produces electric current by vapour generator.The present invention especially provides spent ferric oxide and the useful method that changes iron into of useless carbon energy that makes the available thousands of tons in many places, the whole world.
Claims (18)
1. method with the raw material production iron that contains ferric oxide comprises:
With particle size distribution
Iron oxide-containing materials and particle size distribution less than 2mm
Less than the carbon raw material of 6mm, in industrial reactor, under 900 ℃-1200 ℃ temperature, contact, enough make that iron oxide reduction is an iron duration of contact.
2. the method for claim 1 is characterized in that iron oxide-containing materials
For less than 1mm.
3. method as claimed in claim 2 is characterized in that iron oxide-containing materials
For less than 500 μ m.
4. arbitrary as described above claim described method is characterized in that carbon raw material
For less than 2mm.
5. method as claimed in claim 4 is characterized in that carbon raw material
For less than 1mm.
6. the described method of arbitrary as described above claim is characterized in that duration of contact is between 30 minutes-360 minutes.
7. the described method of arbitrary as described above claim is characterized in that carbon raw material is non-volatile carbon dust.
8. the arbitrary described method of claim as described above, the temperature that it is characterized in that reactor is 1000 ℃ to 1100 ℃.
9. the described method of arbitrary as described above claim is characterized in that it also comprises use external heat source reactor heating.
10. method as claimed in claim 9 is characterized in that electrically heated reactor.
11. the described method of arbitrary as described above claim, it is characterized in that iron oxide-containing materials is contacted the described material that comprises predetermined amount to join in the rotating cylindrical shaped reaction device of rotary oven with carbon raw material, set the speed of rotation and the angle of reactor, make the iron oxide reduction Cheng Tie that the residence time of raw material in reactor enough will be all basically.
12. the described method of arbitrary as described above claim is characterized in that it also comprises to prevent the air admission reactor.
13. the described method of arbitrary as described above claim, it is characterized in that selecting the input speed of iron oxide-containing materials and carbon raw material and the operating temperature of reactor, make the gas release that causes by reduction and airflow on surface speed in the reactor that causes is lower than 2ms
-1
14. the described method of arbitrary as described above claim, it is characterized in that comprising the gaseous emission speed of input speed, temperature of reactor and the reactor of control iron oxide-containing materials and carbon raw material, make the carbon monoxide in the reactor reach the concentration of basicly stable state.
15. the described method of arbitrary as described above claim, it is characterized in that comprising iron oxide-containing materials is contacted with excessive slightly carbon raw material, product iron is separated with excessive carbon raw material magnetic, and the smelting iron product generates the soft steel that purity surpasses 99% mass percent.
16. one is suitable for and passes through particle size distribution
Iron oxide-containing materials and particle size distribution less than about 2mm
At high temperature contact and the industrial reactor assembly of the iron produced less than the carbon raw material of about 6mm, it comprises the common cylindrical reactor that has entrance and exit and install around its longitudinal axis rotation, be used for reactor is heated to the heating unit of temperature between about 900 ℃ to 1200 ℃, be used for reactor is installed to erecting device on the launch vehicle.
17. reactor assembly as claimed in claim 16 is characterized in that, heating unit is the electric heater unit that is positioned at the reactor outside.
18. have the launch vehicle of mounted reactor assembly described in claim 16 or 17.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ZA200606360 | 2006-08-01 | ||
| ZA2006/06360 | 2006-08-01 | ||
| PCT/IB2007/053016 WO2008020357A2 (en) | 2006-08-01 | 2007-07-31 | A method for the commercial production of iron |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101506390A true CN101506390A (en) | 2009-08-12 |
| CN101506390B CN101506390B (en) | 2010-10-13 |
Family
ID=39082422
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2007800309460A Expired - Fee Related CN101506390B (en) | 2006-08-01 | 2007-07-31 | A method for the commercial production of iron |
Country Status (13)
| Country | Link |
|---|---|
| US (2) | US8613787B2 (en) |
| EP (1) | EP2057294B1 (en) |
| CN (1) | CN101506390B (en) |
| AT (1) | ATE506457T1 (en) |
| AU (1) | AU2007285415B2 (en) |
| BR (1) | BRPI0715117B1 (en) |
| CA (1) | CA2659559C (en) |
| DE (1) | DE602007014062D1 (en) |
| ES (1) | ES2365266T3 (en) |
| PL (1) | PL2057294T3 (en) |
| RU (1) | RU2465336C2 (en) |
| WO (1) | WO2008020357A2 (en) |
| ZA (2) | ZA200706355B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103551584A (en) * | 2013-11-02 | 2014-02-05 | 莱芜文博粉末科技有限公司 | Continuous production device for preparing reduced iron powder in one step |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| BRPI0715117B1 (en) | 2006-08-01 | 2016-04-19 | Iron Mineral Beneficiation Services Proprietary Ltd | method for producing iron from a material containing iron oxide |
| WO2023102580A1 (en) | 2021-12-02 | 2023-06-08 | Manic Technology Holdings (Pty) Ltd | Iron recovery |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB487692A (en) * | 1936-12-30 | 1938-06-24 | Kazuji Kusaka | Method of and means for manufacturing iron by direct reduction |
| GB1138695A (en) * | 1965-07-20 | 1969-01-01 | Strategic Patents Ltd | Process for the treatment of finely divided metalliferous material |
| DE1758171B2 (en) * | 1968-04-17 | 1976-09-02 | Metallgesellschaft Ag, 6000 Frankfurt | Process for the production of sponge iron pellets |
| BR7002197D0 (en) * | 1970-04-25 | 1973-04-12 | Metallgesellschaft Ag | PROCESS FOR THE DIRECT REDUCTION OF FINE GRANULATION MATERIALS CONTAINING OXIDIC IRON IN A ROTARY OVEN |
| US4330325A (en) * | 1979-06-22 | 1982-05-18 | The Direct Reduction Corporation | Direct reduction rotary kiln with improved air injection |
| DE3210232A1 (en) * | 1982-03-20 | 1983-09-22 | Metallgesellschaft Ag, 6000 Frankfurt | METHOD FOR THE DIRECT REDUCTION OF MATERIALS CONTAINING IRON OXIDE TO SPONGE IRON |
| JP4330257B2 (en) * | 2000-08-09 | 2009-09-16 | 株式会社神戸製鋼所 | Metal iron manufacturing method |
| BRPI0715117B1 (en) | 2006-08-01 | 2016-04-19 | Iron Mineral Beneficiation Services Proprietary Ltd | method for producing iron from a material containing iron oxide |
-
2007
- 2007-07-31 BR BRPI0715117A patent/BRPI0715117B1/en not_active IP Right Cessation
- 2007-07-31 WO PCT/IB2007/053016 patent/WO2008020357A2/en active Application Filing
- 2007-07-31 EP EP07825975A patent/EP2057294B1/en active Active
- 2007-07-31 CN CN2007800309460A patent/CN101506390B/en not_active Expired - Fee Related
- 2007-07-31 AT AT07825975T patent/ATE506457T1/en not_active IP Right Cessation
- 2007-07-31 ES ES07825975T patent/ES2365266T3/en active Active
- 2007-07-31 CA CA2659559A patent/CA2659559C/en not_active Expired - Fee Related
- 2007-07-31 PL PL07825975T patent/PL2057294T3/en unknown
- 2007-07-31 ZA ZA200706355A patent/ZA200706355B/en unknown
- 2007-07-31 DE DE602007014062T patent/DE602007014062D1/en active Active
- 2007-07-31 AU AU2007285415A patent/AU2007285415B2/en not_active Ceased
- 2007-07-31 RU RU2009104870/02A patent/RU2465336C2/en not_active Application Discontinuation
- 2007-07-31 US US12/375,760 patent/US8613787B2/en active Active
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2009
- 2009-02-02 ZA ZA200900790A patent/ZA200900790B/en unknown
-
2013
- 2013-08-29 US US14/014,340 patent/US9150939B2/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103551584A (en) * | 2013-11-02 | 2014-02-05 | 莱芜文博粉末科技有限公司 | Continuous production device for preparing reduced iron powder in one step |
Also Published As
| Publication number | Publication date |
|---|---|
| DE602007014062D1 (en) | 2011-06-01 |
| BRPI0715117A2 (en) | 2013-06-04 |
| ZA200706355B (en) | 2008-04-30 |
| RU2009104870A (en) | 2010-09-10 |
| ES2365266T3 (en) | 2011-09-27 |
| EP2057294B1 (en) | 2011-04-20 |
| CA2659559C (en) | 2014-07-22 |
| ZA200900790B (en) | 2010-10-27 |
| EP2057294A2 (en) | 2009-05-13 |
| AU2007285415B2 (en) | 2011-03-31 |
| RU2465336C2 (en) | 2012-10-27 |
| WO2008020357A3 (en) | 2008-05-22 |
| ATE506457T1 (en) | 2011-05-15 |
| US8613787B2 (en) | 2013-12-24 |
| US20090260483A1 (en) | 2009-10-22 |
| BRPI0715117B1 (en) | 2016-04-19 |
| CN101506390B (en) | 2010-10-13 |
| US20140033869A1 (en) | 2014-02-06 |
| CA2659559A1 (en) | 2008-02-21 |
| US9150939B2 (en) | 2015-10-06 |
| PL2057294T3 (en) | 2011-09-30 |
| WO2008020357A2 (en) | 2008-02-21 |
| AU2007285415A1 (en) | 2008-02-21 |
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